Process and apparatus for the manufacture of carbon blacks having improved dispersion and platewear characteristics

ABSTRACT

A reaction mixture is formed of a feedstock hydrocarbon and hot combustion gases, the mixture having a composition and sufficient heat content for formation of a carbon black of specific particle size and structure characteristics upon decomposition of the hydrocarbon within the mixture. Before the carbon black is completely formed, the mixture is diluted with a gas which is substantially nonreactive with the carbon black and cooler than the mixture. Agglomeration of the particles of carbon black within the mixture is reduced, and the resultant dispersion and platewear characteristics of the carbon black in printing inks are greatly improved.

United States Patent Heller et al.

[ 1 Feb. 15,1972

Eckert, Morrisville, Pa; Charles L. De Land, West Monroe; Robert W. Dingman,

Monroe, both of La.

[73] Assignee: Columbian Carbon Company, New York,

[22] Filed: Jan. 2,1969

[21 Appl. No.: 788,491

3,235,334 2/1966 He1mers ..23/209.4 3,290,120 12/1966 Wright et 31 3,369,870 2/1968 Ganz et a] ..23/209.4 3,401,020 9/1968 Kester et al ..23/209.4 3,490,869 1/1970 Heller ..23/209.4

Kirk-Othmer Encyclopedia ol Chemical Technology. Vol.

Primary Examiner-Edward J. Meros Att0rneyJ. Richard Geaman [57] ABSTRACT A reaction mixture is formed of a feedstock hydrocarbon and hot combustion gases, the mixture having a composition and sufi'lcient heat content for formation of a carbon black of specific particle size and structure characteristics upon decomposition of the hydrocarbon within the mixture. Before the carbon black is completely formed, the mixture is diluted with a gas which is substantially nonreactive with the carbon black and cooler than the mixture. Agglomeration of the particles of carbon black within the mixture is reduced, and the resultant dispersion and platewear characteristics of the carbon black in printing inks are greatly improved.

20 Claims, 4 Drawing Figures PROCESS AND APPARATUS FOR THE MANUFACTURE OF CARBON BLACKS HAVING IMPROVED DISPERSION AND PLATEWEAR CHARACTERISTICS BACKGROUND OF THE INVENTION l. Field of the Invention This invention relates to carbon blacks which are employed as pigments in rubber, paints, lacquers, and plastics, and more particularly to carbon blacks which are used as pigments in printing inks.

2. Description of the Prior Art For many years carbon black was manufactured chiefly by channel processes in which a gaseous hydrocarbon such as natural gas was partially burned and the resulting carbon black was collected by impingement upon a cold surface. Oil furnace processes, which employ normally liquid hydrocarbons as feedstocks for the carbon black, were subsequently developed and currently permit the manufacture of carbon black at much higher rates, and in a greater variety of grades, at lower process cost.

Great quantities of oil furnace black are used each year as reinforcing pigments for rubber. They are also employed as pigments in inks, paints and the like, but have been used to only a limited extent as a pigment in printing inks. In the printing ink field, oil furnace blacks have been unable to displace channel blacks since the former disperse poorly in ink vehicles and the resulting inks wear down the printing plates at too high a rate.

lnkmakers prefer a carbon black which can be easily and thoroughly dispersed in the ink vehicle. Inadequate dispersion of the carbon black in the ink can result in the filling of recesses and depressions of the printing plate and cause blurring and smudging of the printed image. Heretofore, oil furnace blacks have been characterized by a high content of microscopic agglomerates of the particles, and in order to provide a good dispersion in printing ink the particles in the agglomerates must be dispersed, either chemically or by application of an extraordinary amount of mechanical work. Such additional processing is, however, objectionable and costly to the inkmaker.

Abrasiveness of an ink refers to the rate at which it will wear away the printing plate surface during the printing operation. While the term abrasiveness is used to describe a property of the ink, it carries simultaneously a similar connotation for the ink pigment itself since the abrasive character of the ink is attributed primarily to the pigment contained within it. Thus, a carbon black may be described as either a high or low abrasion product, and will generally be referred to as'being either high or low in platewear." Platewear is of vital interest to the long-run printing operations where thousands of copies of a print are made. Use of a highly abrasive black in the ink can result in platewear rates so high as to require premature shutdown of the printing operation. Loss in operating time and replacement of plates are very costly to the printer.

Oil furnace blacks, although cheaper in price and more readily available than channel blacks, have nonetheless failed to meet the standards of dispersion and platewear achieved with channel blacks. Poor dispersion in printing ink, relative to channel black, has been the general rule for oil furnace blacks. Platewear values of 100-300 percent worse are normally observed when testing an oil furnace black for this property against a channel black at equal color and viscosity.

Numerous methods of aftertreatmenthave been proposed for improving the dispersion and platewear characteristics of oil furnace blacks in printing inks, including the addition of dispersing agents to the ink vehicle andlor the pigment itself, the addition of a compatible oil to the black before it is mixed into the vehicle, and mechanical treatment for reduction of agglomerate size, such as pulverization, fluid energy milling and prolonged milling of the ink mix. All of these methods intend, however, to resolve difficulties which arise due to the presence of the agglomerates in the black, and nomethod has heretofore been proposed which would negate or greatly reduce the occurrence of the agglomerates in the first place.

It is therefore an object of this invention to reduce agglomeration of the carbon black during formation of the particles.

Another object is to provide a carbon black which can be produced directly in a furnace and which without aftertreatment is characterized by outstanding dispersion and low platewear characteristics in printing inks.

Still another object is to produce oil furnace blacks which can be employed as a replacement for channel blacks in printing inks.

These and other objects of the invention will become apparent from the following description and the appended claims.

In carrying out the present invention, the first step is formation of a reaction mixture of a feedstock hydrocarbon and hot combustion gases, the gases being the product-of burning a fluid fuel with a free oxygen-containing gas. The composition and heat content of the mixture are such that a carbon black of specific particle size and structure characteristics is formed upon thermal decomposition of the hydrocarbon by absorption of heat from the hot combustion gases of the mixture. Thermal decomposition of the hydrocarbon within the mixture is allowed to proceed until the desired particle size and structure characteristics of the carbon black have substari tially developed, and the reaction mixtureis then diluted with a diluent gas which is substantially nonreactive with the black and cooler than the mixture. However, the reaction mixture is not chilled with the diluent gas to the extent that continued thermal decomposition of the hydrocarbon is completelyterminated, but reaction conditions are nonetheless altered by the dilution so that high-temperature agglomeration of the particles is greatly reduced.

Although not wishing to be bound by theory, it is felt that the particles tend to agglomerate in the formation zone due to their small particle size and high surface energy after the desired particle size and structure characteristics of the particles are substantially developed. Dilutionreduces the temperature of the reaction mixture below that at which rapid decomposition of residual hydrocarbon would tend to bind the particles together in a weak or secondary structure unit that resists dispersion and causes excessive platewear.

Initially, therefore, the reaction mixture will have a heat content sufficient for forming the desired particle size and structure characteristics of the black, and the diluent gas will be somewhat coolerwhen passed into the mixture. For example, the reaction mixture should be at a temperature in excess of 2,200 F. when forming the particles, and the diluent gas can be at a temperature of about 2,100 F. to about l,400 F., and passed into the mixture at the rate of at least about 0.5 cubic foot per cubic foot of the mixture. However, it will be understood that the diluent .gas can be still cooler, in which case smaller amounts are required for the dilution.

The diluent gas can be the hot combustion products of burning a fluid fuel with a free oxygen-containing gas and wherein the oxygen content has been substantially depleted so that the yield and quality of carbon black is not adversely affected to any serious extent by reaction with excess oxygen. To additional advantage, the diluent gas may comprise the gaseous products resulting from the thermal decomposition of a hydrocarbon to form carbon black, e.g., flue gases from which a carbon black product is separated and which are then normally wasted or burned as a fuel. Accordingly, the diluent gas can be the gaseous products which result from thermal decomposition of hydrocarbon within the aforesaid mixture. the gases being recirculated and introduced into the mixture during reaction of the feedstock hydrocarbon therein. The recirculation can be effected externally of the chamber within which the carbon black is formed,before or after the carbon black is separated from the gases, but more advantageously within the chamber and prior to separation of the carbon black. Thus, a continuously supplied mixture can be reacted to form an aerosol of carbon black in the hot combustion gases and the gaseous products of thermal decomposition of the hydrocarbon, and at least a portion of the aerosol can be recirculated and introduced into the reaction mixture during formation of the carbon black within the chamber.

The invention can be applied to well-known oil furnace black processes wherein the reaction mixture is forcefully injected into an elongated carbon black formation zone and very quickly reacted therein to develop the desired particle size and structure characteristics of the black, Normally, a highly aromatic, high molecular weight hydrocarbon, such as a petroleum residue or creosote oil, is employed as the feedstock for the carbon black, and in order to form a reaction mixture these feedstocks may be forcefully injected into the hot combustion gases as an atomized spray of liquid droplets. An additive, such as an alkali metal compound, may be introduced into the reaction mixture for controlling the structure characteristics of the resultant black. The mixture is forcefully injected into the carbon black formation zone of the furnace to achieve a high degree of turbulence and rapid reaction so that the particle size and structurecharacteristics of the black are quickly established prior to significant expansion and/or dilution of the mixture. To particular advantage, the reaction mixture can be injected into the carbon black formation zone as an elongated, substantially columnar mass having a significantly smaller cross-sectional area than the formation zone. Accordingly, a columnar mass of the mixture having a cross-sectional area not exceeding about one-sixteenth the cross-sectional area of the formation zone can be injected into the zone at a velocity in excess of about 400 feet per second and more advantageously within the range of about 600 to about 1,400 feet per second. The expression substantially columnar mass" may be taken to mean that the reaction mixture is injected into the carbon black formation zone as a mass which may diverge to some extent but which does not quickly expand outward to fill the cross section of the zone. Columnar projection of the mass may be accomplished by directing the flow of the mixture substantially in-line with regard to the projection axis of the mass, rather than causing the mixture to spiral.

By projecting the reaction mixture axially into the elongated formation zone under the above-prescribed conditions, dilution of the mixture can be effected more or less automatically, i.e. a portion of the aerosol which is created within the formation zone, by thermal decomposition of the feedstock, is inspired into the mixture by means ofBernouIli's effect. Accordingly, the mixture is projected into the carbon black formation zone and the feedstock hydrocarbon is thermally decomposed therein to form an aerosol of the carbon black suspended in the hot combustion gases and the gases produced by thermal decomposition of the hydrocarbon. A region of lower pressure exists around the reaction mixture being introduced into the formation zone, and a portion of the aerosol is thus drawn back into this region and is then inspired into the mixture being introduced into the formation zone. Thus, the aerosol which enters and dilutes the mixture flows countercurrently around the columnar mass and then concurrently and into the reaction mixture. Since the aerosol which passes into the mixture should be measurably cooler than the mixture itself, a cooling agent, such as water vapor, may be introduced into the aerosol beforehand. After the carbon black has been completely formed, the aerosol is withdrawn from the formation zone and the carbon black is recovered. The columnar mass of reaction mixture can be projected substantially longitudinally into one end of the elongated carbon black formation zone while the carbon black aerosol is removed from the other end. To particular advantage the formation zone may be vertically elongated, with the columnar mass of reaction mixture being projected upwardly into the lower end of the zone while the aerosol is removed from the upper end thereof.

As previously indicated, the cross-sectional area of the carbon black formationzone should be at least about 16 times greater than the cross-sectional area of the columnar mass of reaction mixture as it enters the formation zOne, but more advantageously the cross-sectional area of the formation zone should be from about 36 to about 400 times greater than the cross-sectional area of the columnar mass.

The hot gases for forming the mixture may be produced within a combustion chamber into which a mixture of a fluid fuel and a free oxygen-containing gas is continuously introduced and burned. The hot combustion gases may then be discharged into an elongated reaction chamber through a restricting orifice aligned substantially axially with respect to the reaction chamber. Both the combustion chamber and the restricting orifice should be adapted for substantially in-line discharge of said gases from the orifice into the reaction chamber, and the reaction chamber should have a cross-sectional area ofat least about lo'times that of the orifice.

In accordance with the present invention, novel carbon blacks can be produced. Oil furnace blacks can be manufactured by direct production which have a surface mean particle diameter within the range of about I50 to about 650 angstoms, a dibutylphthalate absorption (ASTMD 2424-65) within the range of about 40 to about cc. per grams and an agglomerate area below about 500 square microns per square millimeter, and more particularly within the range of about 30 to 300 square microns per square millimeter. Furthermore, carbon blacks can be manufactured by direct production in accordance with the invention which have surface mean particle diameter and dibutylphthalate absorption within c ranges just stated while also having an L crystallite dimension in excess of 15.5 angstroms, and more particularly from 16.0-to l8.0 angstroms. The term manufactured by direction production" may be taken to mean carbon blacks which are recovered and usable directly after formation without additional aftertreatment such as pulverization, fluid energy milling, graphitization or the like.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a horizontal sectional view of a carbon black furnace which may be employed in carrying out the invention, said furnace having an in-line blast combustion chamber connected coaxially with an elongated reaction chamber through a restricting orifice, or choke.

FIG. 2 is a vertical sectional view of the combustion chamber ofFIG. 1 along the line l-l ofFlG. l.

FIG. 3 is a horizontal'sect ional view of a tangential blast combustion chamber which may be employed with the furnace of FIG. 1.

FIG. 4 is a vertical sectional view of FIG. 3 along the line 2-2.

DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1, an elongated carbon black formation zone I, a restricting orifice or choke 2, and a combustion chamber 3 are bounded by an insulating refractory wall 4. A fluid fuel, such as a natural gas, is introduced into the combustion chamber through jets 5 from a fuel supply header 6. A free oxygen-containing gas, such as air, is passed into a bustle 7 and subsequently flows into the blast ports 8. A mixture of the fluid fuel and the free oxygen-containing gas forms in the blast ports and burns within the combustion chamber 3 to form hot combustion gases. A feedstock hydrocarbon, such as a petroleum residue or creosote oil is injected as an atomized spray of droplets into the hot combustion gases within chamber 3 through a sprayer 9. The feedstock hydrocarbon and the hot combustion gases are thus formed into a reaction mixture which is passed through the choke 2 into the carbon black formation zone 1. The feedstock hydrocarbon which is injected into the furnace may contain a structure control additive such as an alkali metal compound, e.g., potassium or sodium chloride or hydroxide.

The reaction mixture of hot combustion gases and the feedstock hydrocarbon is thus forcefully projected through the choke 2 into the carbon black formation zone 1 as a substantially columnar mass 10. The feedstock hydrocarbon is thermally decomposed by heat absorbed from the hot gases to produce an aerosol ll of carbon black suspended in the combustion gases and the gases produced by the thermal decomposition. After the carbon black is completely formed it is removed from the carbon black formation zone through an outlet 12.

Projection of the reaction mixture into the chamber 1 creates a Bernoulli effect which. causes circulation of. the aerosol from the downstream end of the formation zone back toward the columnar mass 10, as indicated by the arrows. The aerosol is thus caused to flow countercurrently with respect to the columnar mass and then concurrently and into mixture therewith shortly after entry of the mass into the formation zone. For controlling the temperature of the aerosol,,and thus the temperature of the gas which enters the mixture and dilutes it, water is injected into the formation Zone through a spray 13.

The reaction mixture is formed having whatever proportions of feedstock hydrocarbon, hot combustion gases, addi tives and the like as may be desired by the operator for making a particular type of carbon black. The necessary proportions and compositions for each type are well known to the skilled artisan.

The point at which the feedstock hydrocarbon is injected into the hot combustion gases by means of the sprayer 9 is somewhat variable, one advantageous sprayer position being shown in FIG. 1. However, the tip of the sprayer may be located closer to the choke 2, within it, or even beyond it, and still produce a suitable reaction mixture. Accordingly, the feedstock hydrocarbon may be partially decomposed into carbon black within the combustion chamber and choke or entirely within the carbon black formation zone 1.

An alternate type of combustion chamber which may be employed with the furnace of FIG. 1 is shown in FIG. 3. Air is introduced tangentially into the chamber 3 through conduit 14. Fuel gas is injected coaxially into conduit 14 through ajet 15. The resultant mixture is burned in chamber 3 to produce a spiralling mass of hot combustion gases which are conveyed to the choke 2 through a frustoconical section 3a of the chamber. It must be pointed out, however, that the angle of the frustoconical section, the diameter of choke 2 and the rate at which the reaction mixture is passed into the choke must be such that the flow of the mixture out of the choke and into the carbon black formation zone is substantially in-line rather than spiraling, since the mixture should enter the formation zone as a substantially columnar mass rather than as an expanding cone.

As previously indicated the carbon black formation zone 1 should have a cross sectional area at least about 16 times greater than the choke and preferably 36 to 400 times as great. Furthermore the reaction mixture should be discharged from the choke at a velocity in excess of about 400 feet per second, and more advantageously within the range of about 600 to about 1,400 feet per second. The heat content of the reaction mixture should be sufficient to effect a reaction temperature of at least about 2,200 F. within the columnar mass prior to introduction of the aerosol as a diluent, and the aerosol should be cooled to a temperature of about 2,100" F. to about l,400 F. before it is inspired into the mixture.

The carbon black formation zone can, to advantage, be vertically disposed since circulation of the aerosol within the furnace is thereby enhanced. The length of the formation zone is not critical. except that it should be sufficiently long to accommodate the length of the substantially columnar massof reaction mixture and permit complete reaction of the hydrocarbon therein to form carbon black. In practice, the formation zone will commonly have a length greater than its diameter and more commonly a length of about 2 to 6 times its diameter.

After the aerosol has been removed from the formation zone I through outlet 12, it may be cooled by means ofa water quench and thenpassed to cyclone separators, a bag filter, or the like for separation of the carbon black from the gases.

Before presenting specific operating examples of the present invention it is appropriate to describe the test methods used to determine the dispersion and platewear properties of carbon black.

A quantitative test has been developed whereby dispersion can be expressed by means of a Comprehensive Dispersion Rating, referred to hereinafter as CDR. In performing the test, two dispersion rating instruments are employed, similar in performance by providing results which differ in magnitude. One instrument is known as the NPIRI gauge It is a flat elongated steel bar having parallel channels approximately 1 inch wide and 8 inches in length inscribed in the flat face of the steel bar. The channels are tapered so that there is a uniform change in the depth of the channels from 1/1000 inch at the deepest end to zero depth at the other end.

The second instrument is similar and is referred to as the Production Club, or PC gauge Like the NF'IRIv gauge it is an elongated steel bar having parallel channels inscribed in the flat face of the bar. The channels of the PC gauge, however, are /z-inch wide and about'6 inches long, uniformly changing in depth from 4/1000 inch to zero depth. The channels of both instruments have index lines adjacent to the channels which subdivide the channels into 10 segments of equal length. The operational procedures are essentially identical for each instrument. A sample of an ink paste is placed at the deep end of one channel. At the same position in the other channel is placed a sample of another ink paste, usually a reference standard. A scraper blade resting on the flat'face of the instrument, simultaneously moves both ink samples from the deep end of the gauge channels toward the shallow end. After the scraper blade has traveled the length of the instrument, the excess ink has been removed, leaving films of ink in both channels, the thickness of the films coinciding with the depth of the channel. I

The visual appearance of the ink films can range from a smooth glossy surface to a dull sandy scratched surface depending on the degree of dispersion of the pigment within the ink vehicle. Ideally, the entire film would be smooth and glossy, indicating perfect dispersion. In practice, however, it is observed that the smooth glossy surface will characterize the deeper channel position while at the more shallow positions, where the ink films are relatively thin, small aggregates of undispersed pigment impart sandiness while larger aggregates which cannot pass under the scraper blade cause a scratched surface in the film. Thus, by comparing the appearance of the films, a skilled technician can readily determine which has the better dispersion. The degree of difference, however, is quite subjective and does not allow one to readily compare a number of ink samples with a meaningful rating assigned to each. To overcome this problem a system of numerical ratings have been developed which assigns quantitative values to the visual elements of dispersion. Such a system employs the following equation to determine the final rating.

CDR=O.4[250( N +N +N +N,+P)] In the above equation, symbolic representations are,

CDR: Comprehensive Dispersion Rating N Channel depth (in microns) where four scratches are first observed.

N Channel depth (in microns) where 10 scratches are first observed.

N Average sandiness intensity between 10 and 25 microns channel depth.

N Average sandiness intensity between 0 and 10 microns channel depth. (Note: Sandiness intensity is determined by comparison with fixed visual standards) Channel depth (in microns) where sandiness first appears.

Values represented by N are taken from inkfilms on the NPIR] gauge while values indicated by P are taken from'films on the PC gauge.

The values derived from the above equation range from 0-100 for the CDR, the value of representing perfect dispersion.

All ink pastes are prepared on a conventional laboratory three-roll mill with roll pressures of 300 p.s.i. Samples are passed through the mill three times, dispersion characteristics being determined after each pass, It should be emphasized at As can be seen, the reference black and the black of Examthis Point that no di persing agents are added to the vehicle or P16 I have essentially the same particle size Structure and sup carbon black either before or during the milling procedure.

As previously indicated, the carbon blacks of the present invention display platewear characteristics markedly superior to conventional furnace carbon blacks. When testing carbon black for potential use in printing ink, platewear is a significant determinant in acceptance or rejection of the candidate black. To perform the platewear test inks are mixed on a laboratory three-roll mill. Felt strips are attached to a flat table surface and grams of ink spread evenly on each felt strip. Printing plate test sections, chrome surfaced electrotype plates approximately 1% inches l l/l6 inches are washed in naphtha, dried and weighed, then mounted on a test machine designed to move the plates along the ink filled felt strips. The machine is set to provide 75 strokes per minute for 12 hours. Every 3 hours an additional 3 grams of ink are placed on the felt strip. After 12 hours the test plates are removed from the test machine, washed in naptha, dried and weighed. The weight loss of the plate is determined. The loss in weight is compared to the loss of a plate representing a reference standard ink, the final platewear being expressed as a percentage of the reference ink.

In the following examples the hydrocarbon feedstocks were petroleum residue oils having the following typical analysis;

UOP K Factor 10.0

EXAMPLE] A vertically disposed furnace generally as shown in FIG. 1 was employed. The carbon black formation zone had a diameter of l8 inches and a length of6 feet. The choke had a diameter of 4.5 inches and a length of 8 inches. Preheated air at 800 F. was passed to the combustion chamber at the rate of 30,000 s.c.f.h. while natural gas was introduced at the rate of 2,000 s.c.f.h. The mixture of air and fuel was burned to produce hot combustion gases which were mixed with the feedstock hydrocarbon to form a reaction mixture which was injected through the choke into the carbon black formation zone as a substantially columnar mass. The feedstock hydrocarbon was sprayed into the choke as an atomized spray of liquid droplets at a rate of 42 g.p.h. (60 F.). 0.04 lbs. of potassium hydroxide was dispersed in each gallon of the feedstock as a structure control additive. Water, at the rate of about 30 g.p.h., was sprayed into the carbon black formation zone from a point located about 7.5 feet downstream of the choke exit, the-water spray being located on the centerline of the furnace and directed toward the choke.

The resultant carbon black is shown in comparison to a reference black produced in accordance with a prior art oil furnace process wherein the reaction mixture spiraled and was passed as an expanding conical mass from an 8-inch choke into a formation zone having a diameter of ll inches and a length of about 10 feet.

lnk Properties [0'1 Carbon in lsuphthnlic Alkyd) face area characteristics, but the black of Example I is superior in dispersion to the reference black. It should be pointed out that none of the blacks shown in these examples was subjected to any form of mechanical aftertreatment such as pulven'zation or fluid energy milling.

CDR values for Pass 1 are indicative of the rate of dispersion, the higher value representing a faster rate. Pass 3 values indicate the degree of dispersion which can be ultimately expected in the finishedink mix. It is significant that the differences between the reference and experimental samples are persistent during both Pass 1 and Pass 3. Frequently a carbon black may show a rapid rate of dispersion as indicated by Pass 1 values but on subsequent passes will show only small improvement resulting in no advantage after Pass 3. In the above example, however, it will be noted that the carbon blacks of the present invention are superior in both rate and degree of dispersion.

EXAMPLE ll A vertically disposed furnace the same as in Example I was employed except that the carbon black formation zone had a diameter of 33 inches instead of 18 inches. Preheated air at 800 F, was passed to the combustion chamber at the rate of 63,000 s.c.f.h. while natural gas was introduced at the rate of 4,200 s.c.f.h. The mixture of air and fuel was burned to produce hot combustion gases which were mixed with the feedstock hydrocarbon to form a reaction mixture which was injected through the choke into the carbon black formation zone as a substantially columnar mass. The feedstock hydrocarbon was sprayed into the combustion chamber as an atomized spray of liquid droplets at a rate of 102 g.p.h. (60 F.). 0.015 lbs. of potassium hydroxide was dispersed in each gallon of the feedstock as a structure control additive. Water, at the rate of about 48 g.p.h. was sprayed into the carbon black formation zone from a point located about 7.5 feet downstream of the choke exit, the water spray being located on the center line of the furnace and directed toward the choke. During the experiment, the temperature within the combustion chamber was about 2,800 F., while the temperatures in the top, middle and bottom of the formation zone were about 2,050 F., 2,010 F., and l,960 F. respectively, the measurements being taken near the wall of the formation zone.

The resultant carbon black is shown in comparison to a reference black which was produced on the same furnace and in the same manner as the reference black of Example 1.

Carbon Black Properties Reference Examplc ll Tinting Strength, %FF I34 I34 Dibutylphthalatc Abs,

ce./ g. 56 68 lndine Adsnrption,ASTM I09 106 lnk Properties (20% Carbon in lsophlhalic Alkyd) CDR-Pass l 49 62 Pass 3 64 84 EXAMPLE Ill The furnace of Example II was used while employing the following'conditions. Preheated air at 180 F. was passed to the combustion chamber at the rate of 70,000 s.c.f.h. while natural gas was introduced at the rate of 3,890 s.c.f.h. The mixture of air and fuel was burned to produce hot combustion gases which were mixed with the feedstock hydrocarbon to form a reaction mixture which was injected through the choke into the carbon black formation zone as a substantially columnar mass. The feedstock hydrocarbon was sprayed into the combustion chamber as an atomized spray of liquid droplets at the rate of 54 g.p.h. (60 F.). 0.033 lbs. of KOl-l was dispersed in each gallon of the feedstock as a structure control additive.

Water, at the rate of about 55 g.p.h. was sprayed into the carbon black formation zone from a point located about 3 inches downstream of the choke exit, the water spray being located on the center line of the furnace and directed away from the choke. During the experiment, the temperature within the combustion chamber was about 2.220 F., while the temperatures in the top, middle and bottom of the formation zone were about 2,240 F., 2,200 F. and 1.980 F. respectively, the measurements being taken near the wall of the formation zone.

The resultant carbon black is shown in comparison to a reference black which was produced on the same furnace as was employed for making the reference black of Example I, the reaction mixture having a somewhat different composition and temperature for production of a finer black.

Carbon Black Properties Reference Example lll Tinting Strength. 7rFF 143 I4! Dihutylpbthalate Abs.

cc./l00 g. 58 60 Iodine Ads., ASTM l90 [67 Ink Properties Carbon in lsophthalic Alkyd) CDR-Pass l 42 64 Pass 3 56 79 EXAMPLE IV The furnace of Example [I was used while employing the following conditions. Preheated air at 800 F. was passed into the combustion chamber at the rate of 41,500 s.c.f.h. while natural gas was introduced at the rate of 2,300 s.c.f.h. The mixture of air and fuel was burned to produce hot combustion gases which were mixed with the feedstock hydrocarbon to form a reaction mixture which was injected through the choke into the carbon black formation zone as a substantially columnar mass. The feedstock hydrocarbon was sprayed into the combustion chamber as an atomized spray ofliquid droplets at the rate of 84 g.p.h. (60 F.). 0.004 lbs. of KOH was dispersed in each gallon of the feedstock as a structure control additive. No cooling water or other cooling agent was injected into the carbon black formation zone during the experiment. The temperature within the combustion chamberwas about 2,460 F., while the temperature throughout the formation zone was below about 1.500 F., but not lower than about l,300 F.

The resultant carbon black is shown in comparison to a reference black which was produced on the same furnace as was employed for making the reference black of Example I, the reaction mixture having a somewhat different composition and temperature for production ofa coarser black.

Carbon Black Properties Reference Example lV Tinting Strength. FF l()l H0 dibutylphthalate Abs.

cc./l00 g. 80 76 Iodine Ads. ASTM 60 58 Ink Properties Black in lso hthalic Alkyd) (DR-Pass I 57 94 Pass 3 71 94 EXAMPLE V The furnace of Example II was used while employing the following conditions. Preheated air at 400 F. was passed to the combustion chamber atthe rate of 58,000 s.c.f.h. while natural gas was introduced at the rate of 3,220 s.c.f.h. The mixture of air and fuel was burned to produce hot combustion gases which were mixed with the feedstock hydrocarbon to form a reaction mixture which was injected through the choke into the carbon black formation zone as a substantially columnar mass. The feedstock hydrocarbon was sprayed into the combustion chamber as an atomized spray of liquid droplets at the rate of 105 g.p.h. (60 F.). 0.0l4 lbs. of 'KOH was dispersed in each gallon of the feedstock as a structure control additive. No cooling water or other cooling agent was injected into the carbon black'formation zone. The temperature within Reference Carbon Black Properties Tinting Strength, kFF Dibutylphthalate Abs., cc./ 1 ()0 g. Iodine. ASTM Ink Properties (257: Black in lsophthalic Alkyd) CDR-Pass l Pass 3 Example V Examples [1, ll], IV and V were prepared on the same furnace and demonstrate the persistence of superior dispersing and platewear characteristics regardless of the type of carbon black produced. The resultant carbon blacks have average arithmetic mean particle size diameters ranging from about 18 to about 33 millimicrons. Furthermore, a comparison of Examples l and II reveals the versatility of the present process when using furnaces of different dimensions but which nonetheless conform to the operating conditions prescribed herein.

In addition to displaying superior dispersing properties in printing ink vehicles, the carbon blacks of the foregoing examples also exhibit marked improvement in platewear which persists throughout the different general types. This is illustrated by the following tabulation in which the carbon blacks of the previous examples are compared to their respective reference blacks for platewear ratings.

The reduced platewear values for the products of the present invention, coupled with dispersion values earlier shown, clearly demonstrates the important combination of characteristics of the present invention.

in the preceding examples, inks were prepared by milling the carbon black into an isophthalic alkyd vehicle. However, the improvements are not restricted to a specific ink vehicle, since similar improvementshave been demonstrated in linseed oils, linseed modified alkyd systems, and quickset ink formulatrons.

EXAMPLE VI The furnace apparatus used in preparing the previously described carbon blacks was designed to impart an in-line flow to the components within the combustion chamber, and,-consequently, to the reaction mixture leaving the choke. Furthermore, in the preceding examples the feedstock hydrocarbon was injected either into the hot gases within the combustion chamber or the choke.

In the present experiment, the furnace had a combustion chamber similar to that shown in FIGS. 3 and 4 of the drawings. The carbon black formation zone had a diameter of 78 inches and .alength of 93 inches. The choke was '5 inches in diameter and 4inches long. Preheated air at 800 F. was fed to 7 F.). 0.04 lbs. of KOH was dispersed in each gallon of the feedstock as a structure control additive. Water, at the rate of about 48 g.p.h. was sprayed into the carbon black formation zone from a point located about 8 feet downstream of the choke exit, the water spray being located on the center line of the furnace and directed toward the choke.

The resultant carbon black is shown in comparison to a reference black which was produced on the same furnace and in the same manner as the reference black of Example I.

Carbon Black Properties Reference Example Vl Strength, lFF I34 135 Dibulylphthalate Abs,

cc./l g. 56 58 Iodine Ads, AS'l M IO) 93 Ink Properties ('7r Carbon in lsophlhalie Alkyd) CDR-Pass 3 74 86 EXAMPLE VII The products of the present invention may be used directly in general purpose ink systems or may be chemically treated for special applications. One special application is in ink systems generally referred to as long flow types. These inks, as their description indicates, are characterized by low viscosity and yield value at high carbon concentrations. Flow properties may be indicated by the distance an ink will flow down an inclined plane in a given period of time. Generally, furnace blacks do not function ideally as pigments for long flow inks due primarily to high-viscosity effects, but with after treatment to modify surface properties they become excellent pigments for this application. One method for after treatment of carbon black with ozone has been described in US. Pat. No. 3.245320.

The furnace of Example II was used to prepare a carbon black for after treatment with ozone. Preheated air at 800 F. was fed to the combustion chamber at the rate of 30,000 s.c.f.h. while natural gas was introduced at the rate of 2,000 s.c.f.h. The mixture of air and fuel was burned to produce hot combustion gases which were mixed with the feedstock hydrocarbon to form a reaction mixture which was projected through the choke into the carbon black formation zone as a substantially columnar mass. The feedstock hydrocarbon was sprayed into the choke as an atomized spray of liquid droplets at a rate of 37 g.p.h. (60 F.). 0.03 lbs. of KOH was dispersed in each gallon of the feedstock as a structure control additive. Water, at the rate of about g.p.h. was injected into the formation zone from a point located about 7.5 feet downstream of the choke exit, the water spray beinglocated on the centerline of the furnace and directed toward the choke. During the experiment, the temperature within the combustion chamber was about 2,000 F., while the temperatures in the top, middle and bottom of the formation zone were about 2,I F., 2,060 F. and l.940 F. respectively, the measurements being taken near the wall of the formation zone.

The resulting carbon black was compared to a long flow black prepared by ozone treatment of an oil furnace black produced in a similar manner as the reference black of Example I. Comparison was made between the reference black, the product of Example VII, and the product of Example Vll after treating with ozone ata ratio of l6 parts carbon black to 1 part ozone.

Example Reference Example Vll VII-Ozone Tinting Strength I32 I35 CDR Pass I 50 69 66 Pass 2 54 75 Abrasion Platewcar) I00 50 34 Viscosity,

Poises I46 I74 I5I Flow, inches/l5 minutes on 30 incline 7.4 2.3 6.4

Iodine adsorption test data has been omitted from the above because surface volatiles, characteristic of the reference black and treated product of Example VII, seriously invalidates the test as an indicator of surface area.

Thus, it is apparent that products of the present invention may be after treated with ozone, so that when incorporated as ink pigments in long flow systems, they impart desirable long flow and low viscosity while retaining the superior dispersing and abrasive properties. 1

EXAMPLE VIII A furnace black with essentially the same particle-size and structure of Example Vll, produced on the same furnace at somewhat higher reactant rates is compared below with a normal furnace black and a channel black of equal particle size.

Reference Reference Example Vlll Furnace Channel (Average 2 Carbon Carbon Tests) Surface Area, M /g. based on electron micrographs) I23 I22 I24 Platewear 220% I009? 87% CDR-Pass I 46 7] 59 Pass 3 52 75 80 Viscosity, Poises 27I 475 400 Color Standard Breyer Blacker This example is intended to show that the carbon blacks of this invention are improved over standard channel carbons in dispersibility and platewear.

Table II lists the blacks of Examples II, V, VII and IX (the latter being produced in a similar fashion to the black of Ex. IV) in comparison to a number of currently produced oil furnace blacks. It can beseen that the a'gglomerate area (Column 5), measured in microns squared per millimeter squared,is considerably less for the carbon blacks of the present inventionthan those produced in accordance with the prior art. Agglomerate area for each of the blacks was determined as follows:

l. 6 mg. of the black was placed in a test tubecontaining 1.5 ml. of chloroform.

2. The mixture was agitated for 30 seconds in a 40kc., watt ultrasonic unit containing 1 /2 inches of water.

3. 0.3 ml. of the above solution was then added to L5 ml. of clean chloroform and agitated again in the ultrasonic unit.

4. The mixture of step (3), above, was run down a glass slide at a 30 angle, one time, using between 0.5 to 0.6 ml. of the solution to cover the full area of the slide.

5. Three slides each were prepared of each sample and 5 micrographs were taken of each slide. From the 15 micrographs six representative areas were selected and printed at 400 magnifications.

6. Each print was measured for agglomerate area per square millimeter with a Zeiss Particle Size Analyzer. The final number shown in Column 5 was the average value obtained from the six areas of step (5).

It can also be seen from Table II that the carbon blacks of Examples V and IX had crystallite L values considerably in excess of 15.5. All carbon blacks contain crystallites, which are subgraphitic butplanar layers of carbon molecules arranged like graphite, usually four to eight planes thick. The dimensions of the crystallites can be determined by X-ray diffraction, L being the length of the crystallite and L being the thickness. Directly produced carbon blacks having an I. dimension in excess of 15.5 have not been produced heretofore, but may be produced TABLE II.-PROPERTI'ES Black 1 2 3 4 5 6 7 8 9 10 11 12 Example VII 13. 7 207 285 117 49 10 2. 4 92 150 77 117 135 R 4 14. 8 240 302 110 1,036 67 4. 5 59 160 58 100 137 13. 7 198 265 124 1, .701 93 4. 8 0 156 50 134 133 16. 8 293 412 81 156 3. 2 93 143 57 63 119 14. 5 359 527 63 519 69 3. 1 89 110 50 58 103 15.1 344 532 63 911 23 7. 1 104 79 78 95 12. 8 283 377 89 1, 670 106 4. 6 76 126 70 64 106 13. 8 280 333 100 87 47 4. 9 78 13.9 359 502 66 10, 656 609 4. 7 82 109 65 44 86 Example II 14.8 36 7 2.5 Example IX 16.1 252 31 3.3

* Similar to Example IV.

Note-1 Crystallite Lo. 3 Surface mean particle diameter inangstroms. per gram. her of agglomulatcs per square millimeter. 8 Light microscope dispersion, percent (ASTM). pllttlultzlzltgtc Abs, t.C./100 gm. 11 Iodine Ads. ASIM. cen

by means ofthe present invention, and have utility as pigments in printing inks.

Surface mean diameter of the carbon blacks was determined by means of the following equation:

60,000 1.83 S.A. (EM) where D, is the surface mean diameter in angstroms and SA.

(EM) is surface area in square meters per gram as determined by means of an electron microscope.

Therefore, what is claimed is:

1. In a process for the manufacture of furnace carbon black by thermally decomposing a feedstock hydrocarbon with heat absorbed during contact with hot combustion gases produced by burning a free oxygen-containing gas with a fluid fuel, the method for producing a carbon black characterized by improved dispersion in an ink vehicle which comprises the steps, in sequence, of:

a. forming a reaction mixture of said hydrocarbon and said combustion gases, said mixture having a composition and sufficient heat content for formation of a carbon black of specific particle size and structure characteristics upon decomposition of the hydrocarbon within said mixture,

substantially developing the particle size and structure characteristics of said carbon black by partial thermal decomposition of said hydrocarbon within said mixture,

. diluting said mixture subsequent to step (b) with a diluent gas having a temperature of at least about l,400 F. but cooler than said mixture and before said carbon black is completely formed by continued thermaldecomposition of said hydrocarbon, said diluent gas being substantially nonreactive with said carbon black and being introduced into said mixture at the rate of at least about 0.5 cubic foot per cubic foot of said reaction mixture.

2. The process of claim 1 in which said mixture of feedstock hydrocarbon and hot combustion gases exceeds a temperature of about 2.200 F. during partial thermal decomposition of the feedstock therein.

3. The process of claim 1 in which the diluent gas is the gaseous product which results from reaction of said mixture to said formation zone.

6. In a process for producing an oil furnace black by dispersing a normally liquidhydrocarbon feedstock within hot combustion gases and thereby producing a reaction mixture wherein the composition and temperature is established for formation of a carbon black having specific particle size and structure characteristics by thermal decomposition of said feedstock within the mixture and said mixture is directed as a substantially columnar mass into an elongated carbon black 9 ABC color.

12 Tinting strength, per- 5 Agglomerate area, microns squared per millimeter squared. 4

7 Average agglomcrate size in microns.

2 Arithmetic mean particle diameter in angstroms. 4 EM surface area in square meters formation zone of the furnace wherein the hydrocarbon is thermally decomposed by absorption of heat from the hot combustion gases and aerosol is produced in said formation zone of said carbon black suspended in said hot combustion gases and the gases produced by thermal decomposition of said feedstock, the method of producing a carbon black characterized by improved dispersibility in an ink vehicle which comprises:

a. projecting said columnar mass substantially axially into one end of said formation zone at a velocity of at least about 400 feet per second, the cross-sectional area of said formation zone being at least about l6 times greater than the cross-sectional area of said mass as it enters said zone, the flow of the constituents of said mass being directed substantially in-line with the projection axis of the mass, recirculating a portion of said aerosol to the space in said formation zone surrounding the columnar mass and thus inspiring the recirculated portion of said aerosol into said columnar mass, said recirculated portion of said aerosol being cooler than the constituents of said columnar mass, removing said aerosol from said formation zone after formation of the carbon black is essentially completed and separating and recovering the carbon black, thereby reducing the high temperature agglomeration of the carbon black so that the dispersion and, platewear, characteristics thereof are improved.

7. The process of claim 6 in which the temperature of the columnar mass entering the formation zone is at least about 2,200 F.

8. The process of claim 6 in which the cross-sectional area of the carbon black formation zone is within the range of about 36 to about 400 times as great as the cross-sectional area of the columnar mass as it enters said zone.

9. The process of claim 6 in which the columnar mass is projected into said formation zone at a velocity within the range of about 600 feet per second to about 1,400 feet per second.

10. The process of claim 6 in which the aerosol which is recirculated is first cooled byintroduction of a cooling agent.

11. In a carbon black furnace having a combustion chamber wherein hot gases are produced by the ignition of a continuously supplied mixture of a fluid fuel and a free oxygen-containing gas, and a restricting orifice through which hot combustion gases are discharged from said combustion chamber, said combustion chamber and said orifice being adapted for substantially in-line discharge of said gases from the orifice at a velocity of at least about 400 feet per second, andmeans for dispersing a feedstock hydrocarbon into the hot gases discharged from the orifice, the improvement which comprises an elongated reaction chamber wherein the feedstock hydrocarbon is thermally decomposed to form a Suspension of carbon black in the hot combustion gases and the gaseous products of thermal decomposition of the feedstock, said reaction chamber being in communication with said restricting orifice and aligned substantially axially therewith. the cross-sectional area of the reaction chamber being at least about 16 times the cross-sectional area of said orifice, and a discharge outlet leading from said reaction chamber for removing the carbon black suspension therefrom.

12. The apparatus of claim 11 in which the reaction chamber has a length which is at least about as great as the diameter thereof, said restricting orifice communicates through one end of said reaction chamber, and said discharge outlet leads from the other end thereof.

13. The apparatus of claim 12 in which the length of the reaction chamber is from about 2 to about 6 times the diameter thereof.

14. The apparatus of claim 12 in which the reaction chamber is vertically disposed.

15. The process of claim 1 in which said reaction mixture is forcefully injected into a carbon black formation zone of a furnace wherein said hydrocarbon is thermally decomposed to form said carbon black by absorption of heat from the hot combustion gases, producing within said formation zone an aerosol of said carbon black suspended within said hot combustion gases and the gases which result from thermal decomposition of said hydrocarbon, recycling a portion of said aerosol within said formation zone, introducing the recycled portion of said aerosol into said reaction mixture as said diluent gas, said recycled portion of the aerosol being cooler than the reaction mixture which is forcefully injected into the furnace, and thereby diluting and cooling the reaction mixture with the recycled portion of the aerosol.

16. The process of claim 15 in which said formation'zone is elongated and said reaction mixture is projected into said formation zone as an elongated. substantially columnar mass having a cross-sectional area significantly smaller than said formation zone, and said recycled portion of said aerosol is circulated countercurrently around said columnar mass and then concurrently and into mixture therewith.

17. The process of claim 2 wherein said diluent gas has a temperature within the range of about 1,400" F. to about 2,l00 F. when introduced into said mixture.

18. The process of claim 7 in which the temperature of said recycled portion of the aerosol which is inspired into the columnar mass has a temperature within the range of about l,400 F. to about 2,100 F.

19. The apparatus of claim 11 wherein the cross-sectional area of said reaction chamber is within the range of about 36 to about 400 times as great as the cross-sectional area of said orifice.

20. The apparatus of claim 11 wherein said orifice is adapted for discharge of said gases at a velocity within the range of about 600 feet per second to about 1,400 feet per second.

ggyggg UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,642,446 Dated r ary 15, 1972 1nventor(s) George L.Heller,Frank J.Eckert,Charles L.DeLand,Robert W.

Dingman It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

ASSIGNEE: Delete "Columbian Carbon Company" Insert CITIES SERVICE COMPANY Signed and sealed this 1st day of August 1972.

(SEAL) Attest:

EDWARD MELETCHEJR ,JRQ ROBERT GOTTSCHALK Attes ting Officer Commissioner of Patents 

2. The process of claim 1 in which said mixture of feedstock hydrocarbon and hot combustion gases exceeds a temperature of about 2,200* F. during partial thermal decomposition of the feedstock therein.
 3. The process of claim 1 in which the diluent gas is the gaseous product which results from reaction of said mixture to form carbon black.
 4. The process of claim 1 in which the feedstock hydrocarbon is a highly aromatic, high molecular weight hydrocarbon that is injected into the hot combustion gases as an atomized spray of liquid droplets.
 5. The process of claim 1 in which said columnar mass is projected upwardly and the aerosol is removed from the top of said formation zone.
 6. In a process for producing an oil furnace black by dispersing a normally liquid hydrocarbon feedstock within hot combustion gases and thereby producing a reaction mixture wherein the composition and temperature is established for formation of a carbon black having specific particle size and structure characteristics by thermal decomposition of said feedstock within the mixture and said mixture is directed as a substantially columnar mass into an elongated carbon black formation zone of the furnace wherein the hydrocarbon is thermally decomposed by absorption of heat from the hot combustion gases and aerosol is produced in said formation zone of said carbon black suspended in said hot combustion gases and the gases produced by thermal decomposition of said feedstock, the method of producing a carbon black characterized by improved dispersibility in an ink vehicle which comprises: a. projecting said columnar mass substantially axially into one end of said formation zone at a velocity of at least about 400 feet per second, the cross-sectional area of said formation zone being at least about 16 times greater than the cross-sectional area of said mass as it enters said zone, the flow of the constituents of said mass being directed substantially in-line with the projection axis of the mass, b. recirculating a portion of said aerosol to the space in said formation zone surrounding the columnar mass and thus inspiring the recirculated portion of said aerosol into said columnar mass, said recirculated portion of said aerosol being cooler than the constituents of said columnar mass, c. removing said aerosol from said formation zone after formation of the carbon black is essentially Completed and separating and recovering the carbon black, thereby reducing the high temperature agglomeration of the carbon black so that the dispersion and, platewear, characteristics thereof are improved.
 7. The process of claim 6 in which the temperature of the columnar mass entering the formation zone is at least about 2, 200* F.
 8. The process of claim 6 in which the cross-sectional area of the carbon black formation zone is within the range of about 36 to about 400 times as great as the cross-sectional area of the columnar mass as it enters said zone.
 9. The process of claim 6 in which the columnar mass is projected into said formation zone at a velocity within the range of about 600 feet per second to about 1,400 feet per second.
 10. The process of claim 6 in which the aerosol which is recirculated is first cooled by introduction of a cooling agent.
 11. In a carbon black furnace having a combustion chamber wherein hot gases are produced by the ignition of a continuously supplied mixture of a fluid fuel and a free oxygen-containing gas, and a restricting orifice through which hot combustion gases are discharged from said combustion chamber, said combustion chamber and said orifice being adapted for substantially in-line discharge of said gases from the orifice at a velocity of at least about 400 feet per second, and means for dispersing a feedstock hydrocarbon into the hot gases discharged from the orifice, the improvement which comprises an elongated reaction chamber wherein the feedstock hydrocarbon is thermally decomposed to form a suspension of carbon black in the hot combustion gases and the gaseous products of thermal decomposition of the feedstock, said reaction chamber being in communication with said restricting orifice and aligned substantially axially therewith, the cross-sectional area of the reaction chamber being at least about 16 times the cross-sectional area of said orifice, and a discharge outlet leading from said reaction chamber for removing the carbon black suspension therefrom.
 12. The apparatus of claim 11 in which the reaction chamber has a length which is at least about as great as the diameter thereof, said restricting orifice communicates through one end of said reaction chamber, and said discharge outlet leads from the other end thereof.
 13. The apparatus of claim 12 in which the length of the reaction chamber is from about 2 to about 6 times the diameter thereof.
 14. The apparatus of claim 12 in which the reaction chamber is vertically disposed.
 15. The process of claim 1 in which said reaction mixture is forcefully injected into a carbon black formation zone of a furnace wherein said hydrocarbon is thermally decomposed to form said carbon black by absorption of heat from the hot combustion gases, producing within said formation zone an aerosol of said carbon black suspended within said hot combustion gases and the gases which result from thermal decomposition of said hydrocarbon, recycling a portion of said aerosol within said formation zone, introducing the recycled portion of said aerosol into said reaction mixture as said diluent gas, said recycled portion of the aerosol being cooler than the reaction mixture which is forcefully injected into the furnace, and thereby diluting and cooling the reaction mixture with the recycled portion of the aerosol.
 16. The process of claim 15 in which said formation zone is elongated and said reaction mixture is projected into said formation zone as an elongated, substantially columnar mass having a cross-sectional area significantly smaller than said formation zone, and said recycled portion of said aerosol is circulated countercurrently around said columnar mass and then concurrently and into mixture therewith.
 17. The process of claim 2 wherein said diluent gas has a temperature within the range of about 1,400* F. to about 2,100* F. when introduced into said mixture.
 18. The process of claim 7 in which the temperature of said recycled portion of the aerosol which is inspired into the columnar mass has a temperature within the range of about 1,400* F. to about 2,100* F.
 19. The apparatus of claim 11 wherein the cross-sectional area of said reaction chamber is within the range of about 36 to about 400 times as great as the cross-sectional area of said orifice.
 20. The apparatus of claim 11 wherein said orifice is adapted for discharge of said gases at a velocity within the range of about 600 feet per second to about 1,400 feet per second. 